Public Environmental Review 2010-2012
Transcription
Public Environmental Review 2010-2012
Public Environmental Report 2010-2012 BP Refinery (Kwinana) Pty Ltd Mason Road, Kwinana, WA 6167 Public Environmental Report 2010-12 Table of Contents Aim and Scope of the PER .................................................................................................... 2 BP Refinery (Kwinana)........................................................................................................... 3 The Refining Process at BP Refinery (Kwinana) .................................................................... 4 Environmental Management System .................................................................................... 5 Environmental Policy ............................................................................................................. 7 Environmental Aspects and Performance ............................................................................. 8 Air Emissions ................................................................................................................. 8 Water Emissions .......................................................................................................... 12 Soil and Groundwater................................................................................................... 17 Solid Wastes ................................................................................................................ 19 Biodiversity .................................................................................................................. 24 Water Usage ................................................................................................................ 26 Public Nuisance............................................................................................................ 28 Verification Statement......................................................................................................... 30 Contact Details.................................................................................................................... 31 Acronym Glossary .............................................................................................................. 32 Page 1 of 33 Public Environmental Report 2010-12 Aim and Scope of the PER BP Refinery (Kwinana) periodically produces an externally verified Public Environmental Report (PER) as part of the site’s commitment to openly report the company’s environmental performance. This document aims to report the environmental aspects of the Refinery’s operations that are of public interest and relevance. This externally verified report covers the environmental performance of the Refinery from 2010 to 2012. The Public Environmental Report is updated every three years and is made available to the public via the Internet. The process of refining crude oil characteristically has many environmental aspects and potential environmental impacts. This document will outline all relevant environmental aspects and any associated impacts of the Refinery’s operations. BP Refinery (Kwinana) defines ‘relevant’ environmental aspects as those of general public interest, those which have exceeded environmental permit limits and those which BP Refinery (Kwinana) considers significant. The PER will explain the sources of these relevant environmental aspects and how they are managed to minimise and prevent environmental impacts. Page 2 of 33 Public Environmental Report 2010-12 BP Refinery (Kwinana) BP Refinery (Kwinana) has been processing crude oil since 1955 and is Australia’s largest refinery. It is one of only six operating refineries in Australia and is located approximately 35 km south-west of Perth (the capital city of Western Australia). The Refinery sits on the edge of the natural deepwater harbour of Cockburn Sound. The Refinery is situated within the Kwinana Industrial Area and is the most isolated refinery in the world, employing approximately 450 BP staff and 400 contractors. The Refinery is able to process many different types of crude and produces a broad range of transport The location of BP Refinery (Kwinana). fuels and other petroleum products to stringent environmental standards. It produces LPG, petrol, diesel, kerosene, jet fuel, avgas, Opal (a low aromatic fuel), heating oil and Bitumen. Approximately 65 percent of the Refinery’s products are transported by pipeline to BP terminals at Kewdale and Fremantle, and a third party terminal, owned and operated by Coogee Chemicals Pty Ltd, for distribution throughout Western Australia. The remaining 35 percent of products are exported by ship to markets in the remainder of Australia, and internationally to South-east Asia. A relatively small amount of Liquefied Petroleum Gas (LPG), bitumen and sulphur is distributed by road transport. Since its original construction BP Refinery (Kwinana) has undergone many upgrades and additions to improve the range of crudes it can process, the range and quality of products it can produce and its overall environmental performance. Currently the Refinery Nameplate Capacity (NC) is 146 kilo barrels of crude per day. Page 3 of 33 Public Environmental Report 2010-12 The Refining Process at BP Refinery (Kwinana) Crude oil arrives at BP Refinery (Kwinana) via ship, with a small proportion arriving via road. Prior to processing, all crude that is received by the Refinery is stored within crude storage tanks. In this raw state crude oil is of little value to customers, therefore it must be refined using a combination of pressure, heat and catalysts in order to convert it into useable hydrocarbon products. The main refining processes that convert crude oil into finished useable products are separation and conversion, with some products requiring further purification via the removal of sulphur. The first step in the refining process is to separate the crude oil into its naturally occurring components. Crude oil is pumped from storage tanks into one of two Crude Distillation Units (CDUs) where it is heated to remove the lighter material. Just as water goes from liquid to vapour at 100°C, each type of hydrocarbon changes from liquid to vapour at its own specific temperature range. This allows for separation through the distillation process. Products from the distillation tower range from light gasses at the top, to very heavy viscous liquids at the bottom. These separated products are still unfinished and require further processing to become ‘valuable to customers’. Although the distillation process is able to effectively separate the crude into unfinished products, the proportions of products that exist in raw crude oil do not naturally occur in the proportions that are demanded by consumers. In most cases there is too little petrol and too much heavy oil. Conversion processes modify products using catalytic reactions to convert low value heavy oil into higher value gasoline. Some products also require the removal of sulphur. Sulphur removal produces elemental sulphur and water. The sulphur is sold as feedstock for other industries. Finished products leave the Refinery via pipeline, trucks or ships to be sold to consumers. BP Refinery (Kwinana) ensures all products that leave the Refinery meet quality specifications under the federal Fuel Quality Standards Act 2000 and environmental standards under the State’s Environmental Protection (Petrol) regulations 1999. This ensures that clean fuels are supplied to consumers. Diagram showing crude processing at BP Refinery (Kwinana). Page 4 of 33 Public Environmental Report 2010-12 Environmental Management System It is a commitment of BP Corporate that all of BP’s operating sites have a certified EMS based on the ISO 14001:2004 standards. Under these international standards the Refinery’s EMS aims to achieve: Compliance with legislation and regulations, Continual improvement, Management of significant environmental issues and Prevention of pollution. The purpose of the EMS is to provide a structured transparent and auditable framework to manage environmental issues. BP Refinery (Kwinana) first achieved ISO14001:2004 certification of its EMS in 1999, and was most recently recertified in January 2012. The Refinery will continue to undergo regular and comprehensive audits to maintain this certification. Regular audits help to identify the strengths and improvement opportunities in the operation of the Refinery’s EMS. Therefore, the Refinery’s EMS is a continual improvement process of planning, implementing, checking and reviewing. The continual improvement process of the Refinery’s EMS. Page 5 of 33 Public Environmental Report 2010-12 The Refinery’s ISO 14001 EMS Certification. Page 6 of 33 Public Environmental Report 2010-12 Environmental Policy Page 7 of 33 Public Environmental Report 2010-12 Environmental Aspects and Performance An environmental aspect is an element of an organisation’s activities, products or services that can interact with the environment. An environmental aspect has the potential to have an environmental impact, which is any change to the environment, whether adverse or beneficial, that results from an organisation’s operation. The general categories of environmental aspects at BP Refinery (Kwinana) are: Air emissions Water emissions Soil and groundwater contamination Solid waste disposal Biodiversity Water usage and Public nuisance (noise and odour) Air Emissions Air emissions are one of the Refinery’s most significant environmental aspects. At all oil refineries a level of air emissions is an inevitable result of the combustion processes that are required to refine crude oil. Emissions to the air from the refining process have the potential to contribute to local and global environmental impacts if not managed adequately. Management of air emissions at the Refinery involves a combination of emission monitoring techniques and on-going design reviews to ensure that the processes and equipment used onsite help to minimise the Refinery’s air emissions. Sulphur Oxides (SOx) SOx are released by the burning of fuels containing sulphur. They are emitted from the Refinery from several sources, with the main ones being the Residue Cracking Unit (RCU) and the Sulphur Recovery Units (SRUs). SOx (tonnes/yr) Management of Air Emissions 5000 4500 4000 3500 3000 2500 2000 1500 1000 500 0 Historical Average 2004-9 SOx emissions are managed in a number of ways at BP Refinery (Kwinana). Firstly, the Refinery uses natural gas to feed its 2010 2011 2012 furnaces as a supplement to fuel containing sulphur in order to reduce SOx emissions. Annual SO emissions from BP Refinery x The Refinery also uses two SRUs which are (Kwinana). part of the system used to remove sulphur from the Refinery’s products and convert it to pure sulphur. The recovered sulphur is then Page 8 of 33 Public Environmental Report 2010-12 recycled and used in the manufacture of fertilisers by other companies. SOx emissions are constantly monitored by Continuous Emissions Monitors (CEMs) on both of the SRUs and the RCU. These provide live monitoring of emissions and help to aid in the daily management of feedstock and process conditions. The management of feedstock involves the selection of sweet or sour crudes (low sulphur content or high sulphur content) and the subsequent configuration of the refining process to suit the type of crude being processed (for example a crude with high sulphur will require additional sulphur removal). Environmental performance for SOx emissions was consistent with historical levels in 2010 and 2012. The increase in 2011 was due to the processing of crude with high sulphur content. 900 Historical Average 2004-9 800 NOx (tonnes/yr) Nitrogen Oxides (NOx) NOx are formed from the nitrogen and fuel in air during combustion processes. They are mainly emitted through the Refinery’s furnace stacks. In comparison to the volume of NOx emissions released by motor vehicles in urban areas, BP Refinery Kwinana and similar industries are a comparatively minor source. 700 600 500 400 300 200 100 The Refinery works to minimise NOx 0 emissions by using natural gas to 2010 2011 2012 supplement furnace fuel as it contains a lower concentration of nitrogen. Where Annual NO emissions from BP Refinery x appropriate the Refinery selects low NOx (Kwinana). burners in the sites furnaces. The Refinery’s Continuous Catalytic Reformer is one example of a unit that was built with all low NOx burners in order to reduce emissions. NOx emissions from those units which still have traditional furnaces are managed by maintaining optimal levels of excess oxygen in the flue gas. Excess oxygen helps to keep temperature low so that less of the nitrogen in the air is converted to NOx. Environmental performance for NOx emissions was consistent with historical levels. Carbon Dioxide (CO2) CO2 contributes to a group of gases referred to as ‘Green House Gases’. At the Refinery, it is formed by the combustion of materials containing carbon. CO2 emissions from BP Refinery (Kwinana) are linked to the sites energy consumption. The Refinery has an ‘Energy Strategy’ that monitors and implements projects to improve the sites energy efficiency. One project that has been implemented as part of the Energy Strategy is the ‘no economic flaring’ policy. This policy requires the Refinery to only operate to the level at which it can use all fuel gas produced. Other, indirect emissions are managed through projects which aim to reduce energy use and improve energy efficiency. Page 9 of 33 Public Environmental Report 2010-12 Historical Average 2004-9 800000 700000 CO2 (tonnes/yr) The Refinery also offsets its carbon emissions though Pine Tree plantations in the Southwest of Western Australia. The trees act as a carbon ‘sink’, allowing for the sequestration of CO2. In addition, to offsetting CO2 emissions the tree plantation is helping to deal with salinity problems in the south-west of Western Australia. The planting of deep rooted trees helps to lower the water table and reduce the seepage of saline waters to the soil surface. Environmental performance for CO2 emissions was consistent with historical levels. 600000 500000 400000 300000 200000 100000 0 2010 2011 2012 Annual CO2 emissions from BP Refinery (Kwinana). Volatile Organic Compounds (VOC’s) VOC’s are comprised of a variety of compounds that vaporise at ambient temperature and pressure. They are emitted from the Refinery’s storage tanks, the sewer systems, process units and leaking valves/flanges. Fugitive VOC emissions are managed by the site’s Leak Detection and Repair 1800 Program, where fugitive VOC leaks are 1750 systematically detected and leaking equipment repaired or replaced. The 1700 Refinery also has a program in place which 1650 ensures that all new valves use environmentally friendly ‘valve packing’ 1600 (have low leak potential). VOC emissions in 1550 2010 were significantly higher than 2010 2011 2012 historical levels. This increase was due to the waste heat recovery boiler in the RCU Annual VOC emissions from BP Refinery (Kwinana). being offline for an extended period of time. Additionally, a new VOC emission source was introduced to the calculation in 2010 which accounts for approximately 20% of the observed increase. Historical Average 2004-9 VOCs (tonnes/yr) 1850 Page 10 of 33 Public Environmental Report 2010-12 Particulate Matter (PM) PM is small airborne particles. The major source of particulate emissions at BP Refinery (Kwinana) is the RCU. Particulate Matter <10µm (tonnes/yr) PM emissions from the RCU are managed Historical Average 2004-9 through the use of cyclones and a filtration 140 system. Additionally, In 2012 BP Refinery 120 Kwinana had a major Turn Around event (TAR) 100 during which maintenance was conducted and 80 improvements were made to the RCU to help to reduce future PM emissions. Two 60 improvements were made, the first being the 40 replacement of the Polutrol cyclone to 20 improve performance. The second, the 0 procurement of a spare Pall filter element. In 2010 2011 2012 the past PM emissions have increased during the maintenance and cleaning of the Pall filter Annual PM10 emissions from BP Refinery element. This increase in PM emissions can (Kwinana). now be minimised as the two Pall filter elements can simply be rotated out resulting in significantly less filter downtime. Environmental performance for particulate matter has improved from historical levels. Overall Environmental Performance for Air Emissions The drop observed for all emissions in 2012 is in part attributed to a reduction in crude processing during the 2012 TAR, which is a Refinery maintenance/shutdown event. BP Refinery (Kwinana) had five environmental permit violations related to particulate emissions during the 2010 to 2012 period. There was one permit violation in 2010, one in 2011 and three in 2012. The violations were related to the start-up of the CO Burner and RCU and equipment malfunction. There was one environmental permit violation for SOx, during the 2010 to 2012 period. Total Refinery SO2 exceeded the environmental permit limit in May 2010. This exceedance was attributed to an unexpected power outage. All environmental permit exceedances are investigated and corrective actions are put in place to reduce the probability of a reoccurrence. Page 11 of 33 Public Environmental Report 2010-12 Water Emissions One of the by-products of the refining process at BP Refinery (Kwinana) is water. The Refinery discharges two types of water, process waste water and salt cooling water (SCW). Process waste water is produced during the refining process. The single largest flow is the crude oil desalting process where the crude is washed prior to distillation. Other smaller sources include sour water and boiler blow downs. All of the waste water generated from these sources is collected by the Refinery’s Sewer System. This water is treated as contaminated waste water or ‘oily waste water’. Storm water on the process unit areas is also collected in the Refinery’s Sewer System. All waste water that travels through the Refinery Sewer is treated by the Refinery’s Waste Water Treatment Plant (WWTP). The WWTP uses a combination of physical, physiochemical and biological processes to treat waste water in accordance with the Refinery’s environmental permit. Once treated the water is discharged approximately 4 km offshore via the Sepia Depression Ocean Outlet Landline (SDOOL). The Refinery maintains a backup outlet that discharges to Cockburn sound. The Cockburn Sound outlet has not been used since the commissioning of the SDOOL line in 2009. The Location of the Sepia Depression Ocean Outlet (SDOOL). The Refinery maintains a once through Salt Cooling Water (SCW) system. Sea water is pumped from Cockburn Sound, passes through the Refinery to cool hydrocarbon streams and is then discharged back into Cockburn Sound. Under normal operations the SCW does not come in contact with hydrocarbons as heat is transferred via thermal conduction across tube bundles. However, in the event of a fault the Refinery’s gravity separators remove oil Page 12 of 33 Public Environmental Report 2010-12 to prevent its discharge to Cockburn Sound. The SCW system discharge is routinely monitored as per the conditions of the site’s Environmental Permit. There were no permit violations during the reporting period, as such the remaining section for water emissions will focus on the environmental aspects associated with process water management. Process Waste Water Treatment Plan The first stage of treatment at the WWTP is primary oil removal, where gross oil and solids are removed by the American Petroleum Institute (API) Separator. The recovered oil is sent back to the Refinery for reprocessing. All waste water then passes through the Equalisation Tank where it is kept for an extended period of time. The Equalisation Tank homogenises the quality of water flowing through to the remaining units. At this point pH is checked and adjusted as necessary. Following equalisation, the water Some of the micro-organisms in the ASUs enters the secondary de-oiling section of the that help to break down contaminants in the plant, which removes suspended sediment process waste water. and oil particles. This is called the Dissolved Air Flotation Unit (DAF). Following sediment and oil removal the waste water passes through the biological section of the plant, the Activated Sludge Units (ASUs). Microorganisms in these units break down dissolved contaminants and nutrients. The ASU’s contain naturally occurring micro-organisms that feed on the contaminants in the waste water. In the presence of oxygen, the contaminants are converted to water, carbon dioxide and nitrogen gas which can be discharged safely into the environment. The water then passes through the clarification section, where suspended solids settle and are removed. Prior to discharge the treated process water is monitored as per the conditions of the Refinery’s Environmental Permit. Dissolved Air Flotation Upgrade 2011 In 2012 BP Refinery (Kwinana) received a Helios Award for improvements made to the Dissolved Air Flotation (DAF) Units. The Helios Awards are BP’s global recognition programme. The awards are given to BP projects that demonstrate commitment to BP’s values. The Refinery’s winning entry demonstrated the site’s commitment to both safety and environmental responsibility. The Refinery must have at least one of the two DAF Units running at all times. Prior to the improvements, the dual DAF System The Refinery’s Helios Award winners. Paul Troost, Doug Sweetman and David Lee. Page 13 of 33 Public Environmental Report 2010-12 was very unreliable and each Chain Scraper had to be rebuilt every year. The rebuild put the Refinery’s maintenance crew at risk and meant that the system was not operating optimally. The improvements have greatly increased the run time between overhauls, from 11 months to 2 years. It has also reduced the time required for each overhaul from 11 weeks to 3 weeks. The improvements have increased the reliability and effectiveness of the DAF system and have thereby improved the efficiency and environmental performance of the Refinery’s WWTP. Management of Water Emissions The process water produced during the refining process can potentially contain high levels of contaminants. These contaminants originate from crude oil or result from chemical reactions during the refining process. Some key aspects are outlined below. Hydrocarbons (kg/yr) Hydrocarbons Historical Average 2004-9 1400 The Refinery manages its process water effluent to minimise hydrocarbon 1200 emissions. Management involves 1000 maintaining the processes that produce water and optimising the treatment 800 efficiency of the WWTP. Free oil is 600 removed from the process water through 400 the physical and physiochemical processes of the WWTP. Oil dissolved in the process 200 water is biologically treated in the final 0 stages of the WWTP. Process water is 2010 2011 2012 monitored for hydrocarbons prior to discharge and must meet the conditions of Annual Hydrocarbon emissions from BP the environmental permit. Performance for Refinery (Kwinana). hydrocarbon emissions has been consistent with historical levels, with the exception of 2012. This can be attributed to a major overhaul of one of the ASUs during 2012. COD/BOD Chemical Oxygen Demand (COD) is a measure of the amount of oxygen required to chemically oxidise contaminants. COD does not differentiate between biologically available and inert matter. Biochemical (or biological) Oxygen Demand (BOD) is a measure of the amount of oxygen required by the biota to oxidise constituents in water. The concentration of COD and BOD in treated process water is managed by controlling the process water input to the WWTP and by optimising the treatment process. Education and communication within the Refinery is essential. Unit Operators are required to control and manage discharges to the Oily Water Sewer System which may contain high COD and BOD concentrations. Good communication between process unit operators and the WWTP operators allows for the management of water inputs. The WWTP can also be adjusted to Page 14 of 33 Public Environmental Report 2010-12 Historical Average 2004-9 58000 57000 56000 55000 54000 53000 52000 51000 50000 49000 48000 Historical Average 2004-9 9000 8000 7000 BOD (kg/yr) COD (kg/yr) maximise the removal of the COD and BOD by changing process conditions on the plant. If the removal of COD and BOD is not considered adequate then the treated waste water can be recycled back through the treatment process for additional treatment. Process water is monitored for COD and BOD prior to discharge and must meet the conditions of the environmental permit. Performance for COD was variable from historic WWTP averages, but an overall improvement was evident over the reporting period. 6000 5000 4000 3000 2000 1000 2010 2011 0 2012 2010 2011 2012 Annual COD and BOD emissions from BP Refinery (Kwinana). TSS (kg/yr) Total Suspended Solids (TSS) TSS is a measure of the mass of particles suspended in the water. TSS in treated Historical Average 2004-9 25000 process water effluent is predominantly carried over from the biological treatment 20000 process. TSS is managed by controlling the 15000 discharges to the WWTP and optimising the treatment plant conditions. The ASUs 10000 within the WWTP are carefully controlled to 5000 maintain optimum environmental conditions to keep the population of micro-organism 0 healthy and alive. The feed to the units is 2010 2011 2012 carefully monitored to prevent high levels of Annual TSS emissions from BP Refinery contaminants entering the system (Kwinana). suddenly. This minimises any shock to the micro-organisms, resulting in reduced TSS discharge. The final clarification stage is optimised to remove the maximum amount of TSS. Process water is monitored for TSS prior to discharge and must meet the conditions of the environmental permit. Emissions levels were above the historical average, but an improvement was evident over the reporting period. Page 15 of 33 Public Environmental Report 2010-12 Total Nitrogen Total nitrogen is the sum of ammonia, organic nitrogen, and nitrate-nitrite. Sources of nitrogen in the process water include; Amine, which is used in the refining process to absorb H2S and CO2, and to control corrosion. Sour Water Stripper effluent and Fire fighting foam from the fire training ground. Historical Average 2004-9 Total Nitrogen emissions are managed by 8000 the Refinery by monitoring the inputs to 7000 the WWTP and optimising the treatment 6000 process accordingly. The Refinery’s WWTP 5000 biological treatment units are specifically 4000 designed to remove nitrogen through the 3000 processes of nitrification and 2000 denitrification. A proportion of the nitrogen 1000 in the process water is converted to 0 nitrogen gas, and this lowers the total 2010 2011 2012 nitrogen discharged from the Refinery to the aquatic environment. The Process Annual Total Nitrogen emissions from BP water effluent is monitored for Total Refinery (Kwinana). Nitrogen prior to discharge and must meet the conditions of the environmental permit. Performance for Total Nitrogen has improved from historical levels, with the exception of 2012. This can be attributed to a major overhaul of one of the ASU’s during 2012. Total Nitrogen (kg/yr) 9000 Overall Environmental Performance for Water Emissions During 2012 the Refinery had a major TAR Event during which many of the units weren’t operating under optimal conditions. Additionally in 2012, there was an overhaul of one of the ASUs in the WWTP. These events affected the waste water influent and the operating conditions of the WWTP. BP Refinery (Kwinana) samples the process waste water effluent on a daily basis to meet environmental permit requirements. Fifteen parameters are analysed on a daily basis and an additional three parameters are analysed twice weekly. During the reporting period there was a total of one limit exceedance and two target exceedances. The limit exceedance occurred in 2012 and was attributed to the start-up of an ASU after a maintenance overhaul. The permit target exceedances, one in 2010 and one in 2012, were attributed to unplanned Refinery operations which resulted in abnormal influent to the WWTP. All environmental permit exceedances are investigated and corrective actions are put in place to reduce the probability of a reoccurrence. Page 16 of 33 Public Environmental Report 2010-12 Soil and Groundwater Past operational activities at BP Refinery (Kwinana) have resulted in the loss of hydrocarbons to ground at several locations across the site. These losses resulted from past operational practises that, due to lack of industry wide knowledge, were considered acceptable at the time. The original design of the Refinery did not include a drainage system in the Crude Oil Tank Farm. As a result, water from the Crude Oil Tanks was drained to ground resulting in the accumulation of hydrocarbons in the substrate. BP Refinery (Kwinana) first became aware of subsurface hydrocarbons in the 1970s when extensive monitoring of the subsurface soil was carried out. On detection, recovery efforts commenced with the use of a vacuum tanker. A recovery program has since developed with a comprehensive network of subsurface hydrocarbon recovery systems. The Refinery’s first priority is to avoid environmental impact to the Cockburn Sound by preventing any further migration of underground hydrocarbons. Additionally, the Refinery aims to remediate the site through the recovery of subsurface hydrocarbons and the treatment of impacted groundwater. There is a “no oil to ground” policy across the Refinery. Management of Soil and Groundwater Contamination The loss of hydrocarbons to ground from past Refinery activities has resulted in the accumulation of hydrocarbons beneath the Refinery. Over time, these losses have resulted in the formation of subsurface hydrocarbon plumes and the subsequent contamination of the soil and groundwater. How the Refinery is working towards remediating the contaminated area and the management actions in place to prevent any further contamination are outlined below. Sub-surface Hydrocarbons Sub-surface hydrocarbons exist in a number of phases (gas, dissolved phase and liquid). The hydrocarbon can change state and become a soil gas that exists in the spaces between the soil particles. When hydrocarbon is in contact with the ground water it may form dissolved constituents, which result in the development of a dissolved phase hydrocarbon plume. Dissolved phase hydrocarbon plumes are of concern at the Refinery as the contamination plumes are mobile and reduce the beneficial use of groundwater as a resource. The hydrocarbon may also remain in its original liquid form. As a liquid it can also exist in different ways within the soil. The liquid may attach to soil particles, or form isolated discontinuous droplets referred to as residual hydrocarbon which cannot move or flow. It can also remain as ‘free hydrocarbon product’ which is mobile and available for recovery. Free-phase hydrocarbon has the potential to migrate and contaminate other soil or water resources, including Cockburn Sound. BP Refinery (Kwinana) is committed to the continuous monitoring, recovery, remediation and management of accumulated hydrocarbons beneath the site. The management and remediation strategy is to prevent the loss of hydrocarbons to ground, recover as much of Page 17 of 33 Public Environmental Report 2010-12 the subsurface hydrocarbon as possible, prevent the offsite migration of hydrocarbons and in the long term, remediate soil that has residual (non-mobile) hydrocarbon contamination. A routine monitoring program has been established to give an early warning of any unseen leaks or hydrocarbon migration. The Refinery has an extensive network of over 200 monitoring wells installed across the site, including wells that are monitored monthly and weekly. The wells are used to monitor the distribution of the subsurface hydrocarbon, to detect any migration of free-phase hydrocarbon and to identify the presence of new leak sources. All crude tanks are also fitted with electronic gauges that monitor the height of the fluid and give an early warning of potential leaks and to prevent tank over-fills. A collection system has been constructed which collects all tank water drainings and directs them to the Refinery’s Oily Water Sewer System which flows directly to the WWTP. All storm water and water used in wash down areas is also collected by the Refinery’s Sewer System. Tank floor leaks are prevented by regular tank inspections. During inspections the tank is taken out of service, internally cleaned and inspected for corrosion. The Refinery has an extensive network of subsurface hydrocarbon recovery systems that have been operating on the site since the early 1980s. Subsurface hydrocarbon recovery systems currently in use on the Refinery include: hydrocarbon recovery trenches/wells, single-phase hydrocarbon The various types of Hydrocarbon Recovery Systems utilised recovery skimmers, solar by the Refinery. powered hydrocarbon recovery units, dual-phase hydrocarbon recovery systems and vacuum enhanced product recovery units. Subsurface hydrocarbons are also recovered from beneath the site using a vacuum tanker. The Refinery also operates two air sparging lines to remediate hydrocarbon impacted groundwater that has the potential to migrate offsite. Air sparging is a remediation technology that involves the injection of air into an aquifer to treat hydrocarbon contaminants dissolved in the groundwater and trapped in soil pores. The monitoring of dissolved phase hydrocarbon concentrations at both air sparging sites continues to confirm that the air sparging systems are effective at reducing hydrocarbon concentrations in groundwater underlying the air sparging lines. Page 18 of 33 Public Environmental Report 2010-12 Environmental Performance BP Refinery (Kwinana) assesses the effectiveness of the subsurface hydrocarbon recovery program, based on equipment utilisation targets and free-phase hydrocarbon availability targets. Utilisation Targets The Refinery’s equipment utilisation targets have been established based on the types of equipment, equipment availability and the annual seasons. The behaviour and distribution of subsurface hydrocarbon is influenced by seasonal variations in the water table elevation, due to rainfall recharge and tidal fluctuations. Fluctuations in the water table can cause the hydrocarbon to be trapped in, or released from pore spaces in the soil. Under high water table conditions, the amount of free-phase hydrocarbon is low as contact with the groundwater causes the hydrocarbon to dissolve into constituents. Under low water table conditions, the amount of free-phase hydrocarbon product increases as water drains from the pore spaces. Recovery efforts are now focussed in areas of the Refinery where the free-phase hydrocarbon is persistent throughout most of the year. The recovery equipment is classified into two groups, non-drawdown recovery equipment and drawdown recovery equipment. Non-drawdown equipment is passive recovery equipment and includes Single Phase Recovery Skimmers and Vacuum Enhanced Recovery Units. Non-drawdown recovery systems are best utilised when water levels are low, usually during the summer and autumn months. Drawdown recovery equipment is active recovery equipment, and includes Dual-Phase Recovery Units and Vacuum Tankers. Drawdown recovery systems are best utilised when water levels are high, usually during the winter and spring months. Essentially, the yearly internal Equipment Utilisation Targets are set by taking into consideration the availability of the different equipment types and allowing for seasonal fluctuations in the water table and its effect on free-phase hydrocarbon availability. The performance against the Equipment Utilisation Targets, which were set during the 2010 to 2012 period are shown in the table below. Sub-surface hydrocarbon recovery Equipment Utilisation Targets and to 2012 period. Summer (Q1) (Dec/Jan/Feb) Equipment Type Actual Actual Actual Target Target 2010 2011 2012 Non-Drawdown 90% 92% 91% 88% 90% Drawdown 75% 99% 98% 100% 75% Winter (Q3) (Jun/Jul/Aug) Equipment Type Actual Actual Actual Target Target 2010 2011 2012 Non-Drawdown 50% 102% 74% 79% 25% Drawdown 85% 100% 100% 100% 85% Percentages for the 2010 Autumn (Q2) (Mar/Apr/May) Actual Actual 2010 2011 99% 91% 100% 100% Spring (Q4) (Sep/Oct/Nov) Actual Actual 2010 2011 87% 44% 87% 96% Actual 2012 98% 100% Actual 2012 87% 100% Page 19 of 33 Public Environmental Report 2010-12 Equipment Utilisation Percentages for 2010 to 2012 period are above the established Equipment Utilisation Targets, indicating the Refinery was optimising its use of free-phase hydrocarbon recovery equipment on the site throughout this period. Availability Targets The Refinery’s free-phase hydrocarbon availability target was introduced in 2011 and takes into consideration where the subsurface hydrocarbon recovery equipment is located on the Refinery in relation to where the free-phase hydrocarbon is located beneath the Refinery. In principle, the Refinery’s subsurface hydrocarbon recovery equipment should only be located in areas of the site where free-phase hydrocarbons are present. The Refinery’s free-phase hydrocarbon availability target is that on a monthly basis, no more than 5% of the Refinery’s operating hydrocarbon recovery skimmers will be deployed in areas of the site where freephase hydrocarbon is not available. Free-phase hydrocarbon availability percentages for 2011 to 2012 are within the established free-phase hydrocarbon availability target, indicating all of the Refinery’s free-phase hydrocarbon recovery equipment was deployed in areas of the site where free-phase hydrocarbon was available during this period. Solid Wastes Solid waste is produced as a by-product of crude processing and its related activities. The types of solid wastes that are generated include tank sludges, contaminated soils, spent catalysts and other spent chemicals, together with general municipal (household) and recyclable wastes. The amount and types of waste produced as a result of operations at BP Refinery (Kwinana), is dependent on unit operation, construction/demolition works and maintenance activities, and consequently varies from year to year. Management of Solid Wastes Waste management is an issue of concern to industry, government and the wider community. There are three major concerns surrounding solid waste management. The first concern is the potential loss of valuable and non-renewable materials that could otherwise be recycled. The second is the use of otherwise valuable land for landfill. The third is the potential impacts of inadequate disposal techniques on groundwater quality and the environment, which can ultimately lead to adverse impacts on human health. BP Refinery (Kwinana) has in place several waste management systems that help to ensure wastes are handled and disposed of in a responsible manner, generation of wastes is minimised and recycling/reuse is maximised wherever possible. As part of the BP Group, the Refinery has a policy to treat wastes in a ‘cradle to grave’ manner. This means that the generation, movement, treatment, storage and ultimate disposal of wastes is documented, controlled and meets all regulatory requirements. The Refinery has developed a Solid Waste Management Plan detailing the typical source, treatment and disposal route for all routine wastes produced by the Refinery. BP Refinery (Kwinana) has in place procedures that Page 20 of 33 Public Environmental Report 2010-12 control the management, handling and disposal of solid waste. The procedures ensure that all wastes are correctly managed and documented. Permits are required when waste is to be relocated from the site of generation, to either a storage or disposal location onsite, or offsite. Solid wastes generated by the Refinery are either disposed of directly offsite, treated onsite and then disposed of offsite, or treated and disposed of onsite. Municipal (household) waste is managed through the use of colour coded bins for recyclables and non-recyclables, emphasis is placed on the importance of reducing the amount of waste generated and personnel are encouraged, where possible, to recycle waste that is produced. For example, in 2012 the environmental team introduced ‘Keep Cups’. As part of this initiative, employees are each given a reusable coffee cup and encouraged to use this at the Refinery’s café instead of A BP Refinery Kwinana ‘Keep paper cups. When employees take the cup with them to Cup’ the café they are given a discount on their coffee. This initiative has helped to reduce the number of paper coffee cups used on site, and therefore reduced the volume of waste produced. Municipal wastes are disposed of offsite at appropriately licenced land fill facilities. Recyclables collected are processed through a materials resource recovery facility. Other solid wastes generated at the Refinery such as oily wastes, spent catalysts and industrial/process waste are managed at the Refinery’s waste management facility. This unique waste management facility is dedicated specifically for the handling, storage and treatment of these types of solid wastes. The Refinery is continually looking for ways to reduce the amount of waste sent to landfill and to minimise any environmental impacts associated with the solid wastes generated by the Refinery. Over the 2010 to 2012 period the Refinery trialled alternative methods to improve the performance of sludge disposal and biodegradation. A new and more efficient online waste management system has also been developed. In 2011 BP Refinery (Kwinana) conducted a composting trial to determine if composting could be used to reduce the levels of hydrocarbon in tank sludge which was too high in hydrocarbon concentration to be safely placed on the Refinery’s Land Farm or landfilled. Sludge containing high concentrations of hydrocarbons was blended with compost amendments. These amendments included green waste, mushroom compost, precomposted organic waste and chicken faeces to ensure adequate nutrient, bacteria, fungi and moisture levels for optimal biodegradation. A unique static composting set up was established in order to minimise odour and reduce management time. Perforated pipe extending from the bottom of the static compost pile was used to aid aeration via convection. Results from the trial found that there was a good reduction in total petroleum hydrocarbons. However, the reduction in aromatic petroleum hydrocarbons was not sufficient enough to support the potential large scale use of this form of composting. Page 21 of 33 Public Environmental Report 2010-12 On left, an illustration of the aeration of a static compost pile via convection through perforated pipes. On right, a photograph of the composting trial set up. In 2012, a trial was conducted in which broad beans were planted in two sections of the land farm with the aim of reducing active tilling of the soil and the need for nitrogen addition while, at the same time, improving soil structure and nutrient retention. As a result of the trial water savings were achieved over the 3 months that the broad beans were growing. This was due to the fact that the crop coverage reduced the need for dust suppression spraying. Nutrients were not added to the areas of the land farm planted with bean crops, however, nutrient levels remained stable in these areas. This indicates that the bean crop was successful at naturally enriching the soil with nutrients while reducing the risk of leeching added nutrients into the groundwater. The 2012 broad bean trial. Broad beans were planted in two of the land farm cells in order improve soil structure and nutrient retention. Additionally in 2012, BP Refinery (Kwinana) developed a new online waste management system. The new system is designed to effectively track waste movements within and out of the Refinery using a waste permit system. It will also be used to manage laboratory analysis results and to produce the data required to generate waste inventories and regulatory reports. Page 22 of 33 Public Environmental Report 2010-12 Total Annual Weight (tonnes) There has been a decrease in the total amount of non-hazardous waste produced by BP Refinery (Kwinana) over the 2010 to 2012 period. However waste generation and offsite disposal differs from year to year due to changing site activities. The demolition of an office building in 2009 generated a large amount of construction and demolition waste which was disposed of over 2009 and 2010. Over this period the site also disposed of historical remediated soil to landfill or for use as clean fill. The mass of soil disposed of offsite has reduced over the three years as the backlog of historical soil has been cleared, this also explains the overall reduction in waste disposal over the 2010-2012 period. Hazardous Waste 45 40 35 30 25 20 15 10 5 0 2010 2011 2012 The total weight and proportions of hazardous solid wastes disposed of at BP Refinery (Kwinana). Total Annual Weight (tonnes) Environmental Performance for Solid Waste Non-hazardous waste (recovery/recycled) 16000 14000 Non-hazardous waste (disposed offsite) 12000 10000 8000 6000 4000 2000 0 2010 2011 2012 The total weight and proportions of nonhazardous solid wastes disposed of at BP Refinery (Kwinana). There was a reduction in hazardous waste from 2010 to 2011, however in 2012 there was a significant increase in the amount of hazardous waste disposed of offsite. This large increase is due to the disposal of contaminated sulphur that was previously stockpiled onsite. The sulphur was accumulated from maintenance shutdowns of the SRU since 1999 and, after much investigation into alternative disposal options, could not be recycled. The Refinery will continue to focus on cleaner and more efficient production to minimise the amount of solid waste that is produced. The Refinery will also continue to seek reuse and recycling options for waste. Page 23 of 33 Public Environmental Report 2010-12 Biodiversity Biodiversity is the variety of all life forms, the different plants, animals and micro-organisms, their genes and the ecosystems of which they are a part. The processes involved in refining crude oil have the potential to impact biodiversity and BP Refinery (Kwinana) recognises its responsibility to protect and maintain the unique balance of native plants and animals in the areas surrounding the site. BP Refinery (Kwinana) is located on the edge of the natural harbours of Cockburn Sound. Originally the area was predominately covered in what is known as the Quindalup Vegetation Complex. This included Herb-lands, Sedge-lands and Acacia Shrub-lands. Today the Refinery still has two patches of native Quindalup Vegetation on site. These areas have been protected from destruction through the prevention of public access. The small areas of remnant vegetation are inhabited by a population of native Southern Brown Bandicoots (Isoodon obesulus fusciventer). This species of bandicoots is classed as a ‘conservation dependant priority species’. In 2012, BP Refinery (Kwinana) established a bandicoot monitoring program. Motion activated cameras were set up around the reserve to capture photos of the shy and mostly nocturnal animals. The monitoring program was developed in collaboration with Coast Care, who has established a long term bandicoot monitoring program at Challenger Beach in Naval Base (Kwinana). The photos captured by the cameras will be used to establish an estimate of population size and structure. The information gathered will be used to help monitor and protect the bandicoot population and their remaining habitat, and to educate and raise awareness. Left: One of many photos of bandicoots captured at the BP Refinery (Kwinana) Site. Right: One of the motion sensored cameras used to capture Bandicoot photos. In 2011, BP Refinery (Kwinana) initiated a formal partnership with Native Arc. The funding provided by the Refinery, was used to buy materials to build enclosures for the three stage rehabilitation of orphaned ducklings. Volunteers from the Refinery helped to build one of the enclosures and assisted in the release of rehabilitated ducks. Over 250 ducklings were Page 24 of 33 Public Environmental Report 2010-12 cared for in that year with a greater than 90% success rate achieved. BP Refinery (Kwinana) continued the partnership in 2012 and the funding provided went towards enclosures for bandicoots and raptors. Volunteers from the Refinery helped to build the enclosures and participated in the release of wildlife as was needed. BP Refinery (Kwinana) Volunteers building wildlife enclosures and helping with the rehabilitation of ducklings at Native Arc, Bibra Lake, 2011. BP Refinery (Kwinana) also initiated a partnership with Coastcare in 2011. Through this partnership, the Refinery adopted a degraded area of coastal dune at the Governor Road Reserve in the City of Rockingham. Over the first two years (2011 and 2012) of this partnership, funding has helped to restore the coastal vegetation at the site. BP volunteers planted native species suited to the coast to improve habitat for native animals and to protect the coastal dunes from erosion. BP Refinery (Kwinana) Volunteers planting native coastal species at the Governor Rd Reserve, July 2011. Page 25 of 33 Public Environmental Report 2010-12 Water Usage Using water is an essential part of the refining process. BP Refinery (Kwinana) requires water for a variety of purposes. For example, it is used to heat and cool the hydrocarbon as it is refined into useable products. Water is also used to remove impurities in the hydrocarbon and to perform maintenance activities. The Refinery utilises a number of different water sources for a variety of different purposes. Steam is used in a number of different areas within the Refinery, it is generated onsite and purchased from the Kwinana Cogeneration Plant. Potable water from the Water Corporation is used for processes requiring high grade water, such as boiler feed water, drinking water, safety showers and eye wash stations. Treated high quality waste water from the Kwinana Water Recycling Plant (KWRP) is used in place of potable water wherever possible. Low grade water, which consists of groundwater and returned/reused process water, is used for other processes. Management of Water Usage BP Refinery (Kwinana) is conscious of the need to conserve water and of its high value as a resource. A focus on water minimisation has increased in recent years in response to reduced rainfall and increasing demands on the local water supply. BP Refinery (Kwinana) participates in the Water Corporation’s Water Efficiency Management Plan (WEMP) program. As part of this plan the Refinery has in place a ‘Water Reuse and Minimisation Program’ which was implemented in 1997. The objectives of the program are: -To reduce total water use (by minimising use and increasing reuse), -To significantly reduce potable water use, and -To achieve zero discharge of process wastewater to Cockburn Sound. This innovative program approaches water management with a whole refinery perspective, whilst at the same time targeting specific areas of high water use. Water use minimisation is an on-going practise within the Refinery, and implementing simple actions on the ground, such as fixing dripping taps and only running hoses when necessary can be effective in minimising water use. In the 1990s BP Refinery (Kwinana) was the largest potable water user in Perth. The Refinery has since decreased its potable water usage to approximately 10% of the 1990’s levels. This significant water saving achievement has been recognised by the Water Corporation, which in 2012 presented BP Refinery (Kwinana) with a Platinum Award for water use. The award Des Gillen accepting the Refinery’s Platinum Award for improved water use efficiency. Page 26 of 33 Public Environmental Report 2010-12 recognises that the Refinery has improved its water use efficiency by more than 50%. Much of this reduction was achieved though substituting the use of potable water, for processes such as steam generation and cooling, with highly treated waste water from the Water Corporation’s Kwinana Water Recycling Plant (KWRP). Environmental Performance for Water Use Average Potable Water Use (kL/Day) 700 600 500 400 300 200 100 0 2010 2011 2012 Average potable water use at BP Refinery (Kwinana). 4500 Average Total Water Use (kL/day) There has been an overall reduction in daily total water use at BP Refinery (Kwinana) over the 2010 to 2012 period. The reduction over this period can be attributed to improvements in the accuracy of the groundwater abstraction measurement. Additionally, improvements in energy efficiency saw a reduction in the amount of steam used by the Refinery from 2010 to 2011. From 2011 to 2012, there was a reduction in the amount of treated waste water from KWRP that was used, this was due to the 2012 TAR (Turn Around or maintenance event) during which many of the Refinery’s process units experienced significant down time, and hence water requirements were reduced. 4000 3500 3000 2500 2000 1500 1000 500 0 2010 2011 2012 Average total water use at BP Refinery (Kwinana). Total water use includes potable water use, groundwater use, KWRP treated waste water use and imported steam use. Despite the decrease in the Refinery’s daily total water use over the 2010 to 2012 period, the Refinery’s use of potable water has remained consistent with typical usage. Temporary issues with the operation of groundwater production facilities in 2012 resulted in potable water being used to supplement the Refinery’s groundwater supply. The large increase in the number of personnel onsite due to the 2012 and 2010 Refinery TARs would have also contributed to the increase in potable water. The Refinery commits to an annual water efficiency target with the Water Corporation as part of the WEMP. The Refinery also sets internal targets for water use as a component of the site’s EMS. Page 27 of 33 Public Environmental Report 2010-12 Public Nuisance Refinery operations have the potential to produce elevated noise and various odours. This has the potential to adversely affect the local environment, in particularly the other industries which boundary the Refinery, and the surrounding residential areas. BP Refinery (Kwinana) manages the various refining processes so that odours emanating from the premises do not unreasonably interfere with the health, welfare, convenience, comfort or amenity of any person at odour sensitive premises. Under the Environmental Protection (Noise) Regulations 1997, BP Refinery (Kwinana) is required to maintain noise levels below acceptable and permitted levels at all times of the day. The significant environmental aspects related to odour and noise emissions are outlined below, along with their potential impacts and how they are managed. Management of Public Nuisance Noise The process of refining crude oil to useful products is complex and requires equally complex equipment which produces noise simply due to the fact that it is made up of moving mechanical parts. Noise is also emitted from pressure drops across equipment from release valves, from high gas/steam flow rates exiting stacks and from the flares. The potential impacts of noise can vary greatly depending on the level and type of noise emitted. Possible impacts can range from behavioural effects such as reduced attention, reduced problem solving ability and disturbed sleep, to more serious hearing impairments and hypertension. Noise emissions from the Refinery are managed using engineering solutions and by managing the operation of equipment. Engineering solutions to control noise are applied to both new and existing equipment. Odour The Refinery is a complex facility with a number of possible sources of odour emissions. This is due to the range of different substances that are used in the refining process. Potentially odorous substances include crude oil, catalysts, cleaning agents, additives and wastes, as well as refining by-products and final products. Human exposure to odour generally results in one of three responses or impacts; these are health effects, annoyance or stress. To manage odour emissions, BP Refinery (Kwinana) has in place an internal Odour Management Procedure. The procedure outlines the characteristics of eight gases which could potentially cause offsite incidents of odour. The characteristics of the odour can then be used to trace the odour back to the particular units which are likely to be the source of the odour. The Odour Management Procedure also outlines how to avoid producing odours, and how to respond in the case of odour detection. Additionally, the Breaking Odorous Lines Procedure provides an overview of the actions to consider before commencing an activity that could potentially result in the venting of odorous substances, including consideration of weather conditions and methods to prevent odours. Page 28 of 33 Public Environmental Report 2010-12 Environmental Performance for Public Nuisance Over the 2010 to 2012 period BP Refinery (Kwinana) received no noise complaints from the surrounding industries or community. Noise emissions have been significantly reduced since 2008 after a silencer was installed on the Residual Cracking Unit (RCU). The RCU stack was previously identified as a dominant noise source within the Refinery. A silencer was subsequently installed in the upstream ducting of the RCU exhaust stack to reduce noise levels. Noise surveys conducted before and after the installation of the silencer, show that the silencer has provided a net reduction of 10 dB in the noise emissions from the unit. BP Refinery (Kwinana) plans to continue making improvements in reducing noise emissions from the Refinery. Future Improvements are focussed on installing noise efficient devices on new projects and addressing The RCU silencer installed in 2008 at BP Refinery high noise point sources on site. (Kwinana). BP Refinery (Kwinana) had no odour complaints from the community during 2010 or during 2012. However in 2011, there were two events that resulted in odour complaints from the neighbouring industrial community. Both of the odour complaint events were investigated with findings resulting in corrective changes to operating procedures. The information gathered from investigations into the causes and sources of odour emissions will help to ensure future odour emissions can be managed and prevented. The Refinery will continue to manage potentially odorous sources and activities to minimise any offsite impact. Page 29 of 33 Public Environmental Report 2010-12 Verification Statement Page 30 of 33 Public Environmental Report 2010-12 Contact Details Should you require any further information, or if you have any questions about this report or BP Refinery Kwinana’s operations in general, please contact us and we will be happy to assist. Contact Information Craig McNaughton Environmental and Dangerous Goods Superintendent BP Kwinana Refinery PO Box 2131 Rockingham, WA 6168 AUSTRALIA Tel: Fax: +61 8 9419 9500 +61 8 9419 9800 Page 31 of 33 Public Environmental Report 2010-12 Acronym Glossary API Unit ASU BOD CEM COD CO2 CDU DAF Unit DEC EMS ISO KWRP NC NOx PER PM RCU SCW SDOOL SOx SRU TAR TSS WEMP WWTP VOCs American Petroleum Institute Unit Activated Sludge Unit Biological Oxygen Demand Continuous Emissions Monitor Chemical Oxygen Demand Carbon Dioxide Crude Distillation Unit Dissolved Air Flotation unit Department of Environment and Conservation Environmental Management System International Standard Organisation Kwinana Water Recycling Plant Nameplate Capacity (Maximum crude oil throughput expressed in kilo Barrels per Day) Nitrogen Oxides Public Environmental Report Particulate Matter Residual Cracking Unit Salt Cooling Water Sepia Depression Ocean Outfall Line Sulphur Oxides Sulphur Recovery Unit Turn Around Event (Shutdown/Maintenance Event) Total Suspended Solids Water Efficiency Management Plan Waste water Treatment Plant Volatile Organic Compounds Page 32 of 33